Form 04584306-Edition 1
3
to handle end of Housing. Grasping Housing with installed screws
downward, sharply strike heads of screws on a sturdy table to
dislodge Cylinder. Cylinder should drop out of Housing after a few
impacts. If it does not, carefully heat alternate sides of Housing until it
is very warm. Using thick, heavy gloves to avoid being burned, grasp
Housing and repeat the attempt to dislodge the Cylinder.
8.
Remove the two Air Port Gaskets (29) and Air Port Gasket Retainers
(30) from Housing.
Disassembly of the Handle
1.
Clamp Trigger Handle Assembly in a copper-covered or leather-
covered vise jaws with Straight Inlet (10) upward.
2.
Using a wrench, unscrew and remove the Inlet as well as the Air
Strainer Screen (19) and throttle Valve Spring (8).
3.
Remove Throttle Valve Assembly (6) and Throttle Valve Plunger (5)
from Handle.
4.
If Trigger (13) must be removed, use an arbor press to push Trigger
Pin (14) from Handle and slide Trigger out of the slot in Handle.
Assembly
General Instructions
1.
Always press on the
inner
ring of a ball-type bearing when installing
the bearing on a shaft.
2.
Always press on the
outer
ring of a ball-type bearing when installing
the bearing in a bearing recess.
3.
Whenever grasping a tool or part in a vice, always use copper-
covered or leather-covered vise jaws to protect the surface of the
part and help prevent distortion. This is particularly true of threaded
members and housings.
4.
Always clean every part and wipe every part with a thin film of oil
before installation.
5.
Apply O-Ring lubricant to every O-Ring before assembly.
6.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean solution and dry it with a clean
cloth.
Sealed or shielded bearings should never be cleaned
.
Work grease thoroughly into every open bearing before installation.
Assembly of the Handle
1.
Position Trigger (13) in Handle (1) and using an arbor press, push
Trigger Pin (6) full length into Handle so that it captures the Trigger.
2.
Clamp Handle in copper-covered or leather-covered vise jaws with
air inlet opening upward.
3.
Remove Oil Chamber Plug (12) and fill reservoir with recommended
oil and replace the plug.
4.
Coat Throttle Valve Plunger (5) with oil and insert it, rounded end
leading, into the inlet hole in Handle.
5.
Install a new Throttle Vavle Face (7) on Throttle Valve (6) and insert
assembly, Valve Face leading, into inlet hole in Handle.
6.
Encircle the cone end of the Air Strainer Screen (9) with large end of
Throttle Valve Spring (8) and insert both parts, Spring leading, into
inlet hole in Handle.
7.
Install Straight Inlet (10) over Strainer Screen in Handle and tighten
Inlet between 20 and 25 ft-lb (27 and 34 Nm) torque.
8.
Remove Handle from vise and test Trigger. If Trigger functions
properly, place assembled Handle aside. If it does not function
properly, disassemble Handle to determine cause of problem.
Assembly of the Motor
1.
Lightly clamp Motor Housing (27) in copper-covered or leather-
covered vise jaws with handle end upward.
NOTICE
Excessive clamping pressure will distort the Motor Housing and
make motor installation extremely difficult. Do not insert the
hammer case end of the Motor Housing more than 1" (25mm) in to
the vise jaws.
2.
Coat inside surface of Housing and outer edge of Front End Plate
(24) with a light film of oil.
3.
Using a long tee hex wrench as an alignment pin, insert Front End
Plate, copper face trailing, into Motor Housing. Align dowel hole in
End Plate with dowel hole at the bottom of motor bore.
4.
Lubricate and insert a new fiber Air Port Gasket Retainer (30) in one
of the air ports inside Motor Housing.
5.
Install an Air Port Gasket (29) in air port against Gasket Retainer with
flat end of Gasket away from Retainer.
6.
Repeat Steps 4 and 5 to install remaining Gasket and Retainer in
other air port.
7.
Coat outside of Cylinder (23) with a light film of oil and using the long
tee hex wrench as an alignment pin to align holes in Cylinder with the
holes in Front End Plate and Housing, insert Cylinder into Housing.
8.
Coat inside of Cylinder and Rotor (20) with a light film of oil and insert
the splined hub of the Rotor through cylinder into Front End Plate.
9.
Coat each Vane (22) with a light film of oil and insert a Vane into each
slot in the Rotor. Vanes are to be installed with curved edge toward
center of Rotor. Spin Rotor to settle Vanes in position.
10. Using a long tee hex wrench to align the hole in Rear End Plate (20)
with hole in Cylinder, insert Rear End Plate, bronze face leading, into
Motor Housing against Cylinder. End Plate is properly seated when
large trailing face of the End Plate is slightly below face of Motor
Housing.
11. Grease Rear Rotor Bearing (19) and install it in recess of Rear End
Plate.
12. Remove alignment pin from assembled motor and install Cylinder
Dowel (26). Dowel is properly seated when end of Dowel does not
protrude above End Plate.
13. Install Motor Clamp Washers (18) against Rear End Plate so that
large outer edge of the Washer contacts End Plate.
Assembly of the Reverse Valve
1.
Inject a small amount of grease into hole in Motor Housing where
Reverse Lock Plunger (34) will be installed. With the grease to hold
them in position, install the Reverse Lock Plunger Spring (35) and
Lock Plunger.
2.
Install a new Reverse Valve Bushing Seal (32) in the annular groove
on the Reverse Valve (31).
3.
Coat Reverse Valve with a light film of oil and install it in Motor
Housing with the side hole nearest to Seal pointed toward Rotor (21).
4.
Position Reverse Lever (33) on Reverse Valve and while using a thin
blade screwdriver to depress Reverse Lock Plunger, push Lever onto
Reverse Valve.
5.
Place a new Handle Gasket (15) on Motor Housing.
6.
Examine Reverse Valve Seal (11) located inside Handle and if it is
nicked, deformed or worn, remove it and install a new Seal.
7.
Fill rotor cavity in Handle with recommended grease and position
Handle on Motor Housing.
8.
Install the four Handle Cap Screws (16) and Lock Washers (17) and
using an alternate tightening pattern, tighten Screws to between 10
and 12 ft-lb (13.5 and 16.3 Nm) torque.
9.
Move Reverse Lever through the forward and reverse positions to
make certain that lever locks in position.
10. Turn assembly in the vise jaws and clamp on Handle with rotor shaft
upward.
11. Grease Front Rotor Bearing (25) and place it over the rotor shaft.
12. Select a socket or piece of tubing that will fit over the outside race of
the Bearing and tap it with the hammer to seat Bearing into Housing.
13. Pack Bearing with additional grease and rotate the rotor shaft. If shaft
dose not rotate smoothly, rap end of the rotor shaft with a soft
hammer to set motor and try to rotate shaft again.
